Investigations into effect of weld-deposition pattern on residual stress evolution for metallic additive manufacturing

Somashekara, M. A.; Naveenkumar, M.; Kumar, Avinash; Viswanath, C.; Simhambhatla, Suryakumar

doi:10.1007/s00170-016-9510-7

Cited by 70 publications

(34 citation statements)

References 27 publications

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“…This technology enables the users to quickly produce complex thin-walled structures such as meta-materials, auxetics, etc. (Similar processes also exist for this purpose [3,4]). The additive manufacturing field has been intensively studied for a decade (see [5,6] for reviews of the literature).…”

Section: Introductionmentioning

confidence: 79%

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Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing

Weisz-Patrault

2020

Additive Manufacturing

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In this contribution, a simplified macroscopic and semi-analytical thermal analysis of directed energy deposition (DED) is presented to obtain computationally efficient simulations of the entire process. Solidification and solid-state phase transitions are taken into account. The model is derived for laser metal powder directed energy deposition, although it can be simply adapted for other focused thermal energy (e.g., electron beam, or plasma arc). The gas flow used for carrying the powder significantly influences cooling conditions, which is included in the model. The proposed simulation strategy applies to multilayer composites with a wide range of shapes in the horizontal plane and arbitrary laser scanning strategies (continuous way, back and forth, etc.). The proposed work provides a simple tool to study the influence of most process parameters, design in-situ experiments and in turn develop optimization loops to reach material requirements and specific microstructures. In-situ pyrometer measurements have been compared to the model, and good agreement has been observed with 2.6% error in average. The model is used to demonstrate the effect of various process parameters for a simple cylindrical geometry and a more complex auxetic cell.

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Section: Introductionmentioning

confidence: 79%

“…This section deals with the derivation of the semi-analytical solution of the heat conduction problem (1) to (3). Because of the alternating algorithm, the volumetric heat Q (i) is assumed to be known in this section.…”

Section: Semi-analytical Solution For the Temperaturementioning

confidence: 99%

Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing

Weisz-Patrault

2020

Additive Manufacturing

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“…The welding speed and welding current can affect heat input, which can also affect the microstructure and mechanical properties [10][11][12][13]. Pulsed gas metal arc welding (P-GMAW) is a method based on electric pulses that was invented in the 1960s by English researchers.…”

Section: Introductionmentioning

confidence: 99%

Stability and Heat Input Controllability of Two Different Modulations for Double-Pulse MIG Welding

Xue

Huang

et al. 2019

Applied Sciences

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Aluminum alloy welding frequently experiences difficulties such as heat input control, poor weld formation, and susceptibility to pore generation. We compared the use of two different modulations for double-pulse metal inert gas (MIG) welding to reduce the heat input required to generate oscillations in the weld pool. The stabilities of rectangular wave-modulated and trapezoidal wave-modulated double-pulse MIG welding (DP-MIG and TP-MIG) were analyzed by examining their welding processes and weld profiles. We found that the transitional pulse in TP-MIG welding results in smoother current transitions, softer welding arc sounds, and a highly uniform fish-scale pattern. Therefore, TP-MIG welding is more stable than DP-MIG welding. The effects of these double-pulse modulation schemes on welding input energy are presented. We propose methods for reducing welding input energy by varying the number of pulses or the pulse base time of low-energy pulse train while keeping the welding current and welding arc stable and unchanged. Compared to DP-MIG welding, TP-MIG welding reduces the input energy by 12% and produces finer grain sizes, which increases weld hardness. Therefore, TP-MIG welding offers a new approach for heat input control in DP-MIG welding of aluminum alloys. The results of this work are significant for aluminum alloy welding.

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“…Armentani et al [26] used a parametric model and the elements birth and death in single-pass butt welded joints to simulate the weld filler variation with time. Somashekara et al [27] studied the effect of area-filling paths on residual stresses developed during twin-wire arc weld-deposition. Cai et al [28] investigated a three-component shielding gas mixture used in tandem with narrow gap pulsed gas metal arc welding (GMAW), and the effect of its composition on arc behaviors and weld formation.…”

Section: Introductionmentioning

confidence: 99%

High-Speed Welding of Stainless Steel with Additional Compensatory Gas Jet Blow Molten Pool

et al. 2018

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To avoid humping bead defects in high-speed welding, this paper proposes the method of an additional and compensatory gas jet blow molten pool. A pulsed metal inert gas high-speed welding test platform was constructed for compensatory gas jet blow molten pool. A total of 304 stainless steel sheets were used as the welding workpieces under equal heat inputs. Two high-speed butt welding processes were conducted and compared, in which the workpieces were welded with and without compensatory gas jets at 154 cm/min and 167 cm/min, respectively. After high-speed welding with compensatory gas jet blow, the weld appearance was straight, uniform, and high-quality, with no humping bead or undercut defects. The macroscopic morphologies and microstructures of cross-sections of the weld at the toe, near the surface, the middle, and the bottom portion all showed the stirring effect of the gas jet on the molten pool and improved grain refinement degrees. Hardness was enhanced in the weld center and the heat-affected zone. At welding speeds of 154 cm/min and 167 cm/min, the fracture load capacities of the welds were increased by 24.9 and 10.4%, respectively.

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Investigations into effect of weld-deposition pattern on residual stress evolution for metallic additive manufacturing

Cited by 70 publications

References 27 publications

Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing

Fast simulation of temperature and phase transitions in directed energy deposition additive manufacturing

Stability and Heat Input Controllability of Two Different Modulations for Double-Pulse MIG Welding

High-Speed Welding of Stainless Steel with Additional Compensatory Gas Jet Blow Molten Pool

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